Slim Solar Module Frame Structure for Thin-Wafer Stability
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Solution Overview
Problem
Conventional solar modules are optimized for mechanical stability and longevity but face increased overall system costs due to transportation costs, which are influenced by the module's volume, necessitating a reduction in thickness while maintaining sunlight collection area and mechanical robustness.
Innovation Solution
A solar module design with a optimized frame thickness ratio of 45000 to 70000 and reduced thickness of 28-32 mm, incorporating reinforcement struts and a thinner glass front cover sheet, along with a frame composed of elongate hollow profiles and spacers for mechanical and electrical support, to achieve reduced volume and weight while maintaining stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the solar module is reduced to lower transportation costs, then the volume and weight are decreased, but the mechanical stability is compromised
Solution Approach 1:
The frame is divided into multiple elongate hollow profiles arranged in a grid pattern, creating segmented structural support throughout the module. This segmentation allows the frame to maintain mechanical stability while using less material overall, enabling thinner module construction without sacrificing strength.
Solution Approach 2:
The frame utilizes hollow profiles that combine multiple materials or structures within a single component. The hollow construction provides structural rigidity while reducing weight and material usage, allowing the module to achieve both reduced volume and maintained mechanical stability simultaneously.
2Length of stationary object
If the frame thickness is optimized to reduce module volume, then transportation costs are lowered, but the structural support capability is reduced
Solution Approach 1:
Rather than increasing overall frame thickness, the design segments the frame into multiple thinner hollow profiles distributed across the module. This segmentation provides equivalent or superior structural support through distributed reinforcement while maintaining optimized frame thickness for reduced volume.
Solution Approach 2:
The hollow profiles are strategically positioned at specific locations where structural support is most needed, such as around the perimeter and at key internal points. This local quality approach ensures structural integrity is maintained at critical areas while allowing the overall frame thickness to be optimized for volume reduction.
3Duration of action of stationary object
If conventional frame designs are used to ensure mechanical stability, then longevity is maintained, but the volume and transportation costs increase
Solution Approach 1:
The conventional solid frame structure is replaced with segmented hollow profiles that provide equivalent long-term mechanical stability through distributed support. This segmentation reduces the overall volume and material usage while maintaining the durability and longevity required for long-term operation.
Solution Approach 2:
The hollow profile construction acts as a composite structure that maintains the mechanical properties needed for long-term stability while reducing volume. The multi-chamber or hollow design provides structural rigidity comparable to solid frames but with significantly reduced material content and volume.
Data Source
Figure 1
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Figure 4a~4b
AI summary
A slim solar module (1) is proposed. It comprises a solar laminate (3) comprising plural solar cells (9) interposed between front and rear cover sheets (13, 15), a frame (5) enclosing the solar laminate (3) and at least one reinforcement strut (7) arranged at a rear surface of the solar laminate (3). A ratio between a frame surface and a frame thickness shall be between 45000 and 70000. For example, the frame may have a thickness of less than 35 mm. Specifically, the frame may have a length of 1665 mm, a width of 991 mm and a thickness of 30 mm. Due to the reduced thickness, the solar module has a reduced volume being beneficial during transport to a destination location. However, the thickness has been optimized to, with the reinforcement struts, still providing for sufficient mechanical stability for the solar module.